System for forming structure on print medium

ABSTRACT

A system for forming a structure on a print medium 1 includes: a print unit (print device) 10 for printing an electromagnetic wave-heat conversion layer for converting electromagnetic waves into heat, on a medium including an expansion layer that expands by heating; an expansion unit (expansion device) 20 aligned laterally with the print unit 10, for expanding the expansion layer by irradiating the medium with electromagnetic waves; and a top plate 30 covering the print unit 10 and the expansion unit 20 from above.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority fromthe prior Japanese Patent Application No. 2016-099151, filed May 17th,2016, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a system for forming a structure on aprint medium for manufacturing a structure.

2. Description of the Related Art

A method of forming, on a medium (e.g. a thermal expansion sheet) havingan expansion layer that foams to expand according to the amount ofabsorbed heat on one surface, an electromagnetic wave-heat conversionlayer for converting electromagnetic waves into heat by printing and, byelectromagnetic irradiation, expanding to raise the part of theexpansion layer where the electromagnetic wave-heat conversion layer hasbeen formed on the medium to manufacture a structure has beenconventionally known (for example, see Japanese Patent ApplicationLaid-Open No. S64-28660, Japanese Patent Application Laid-Open No.2001-150812).

To manufacture such a structure, a device for forming theelectromagnetic wave-heat conversion layer on the medium and a devicefor irradiating the medium with electromagnetic waves are needed.However, no consideration has been made on how to enhance workabilitywhen manufacturing the structure using a system that combines thesedevices.

The present invention has an object of providing a system for forming astructure on a print medium that can enhance workability whenmanufacturing a structure using a system that combines a device forforming an electromagnetic wave-heat conversion layer and a device forirradiating with electromagnetic waves.

SUMMARY OF THE INVENTION

A system for forming a structure on a print medium includes: a printdevice for printing an electromagnetic wave-heat conversion layer forconverting electromagnetic waves into heat, on a medium including anexpansion layer that expands by heating; an expansion device alignedlaterally with the print device, for expanding the expansion layer byirradiating the medium with electromagnetic waves; and a top platecovering the print device and the expansion device from above.

A system for forming a structure on a print medium includes: a printdevice for printing an electromagnetic wave-heat conversion layer forconverting electromagnetic waves into heat, on a medium including anexpansion layer that expands by heating; and an expansion device alignedlaterally with the print device, for expanding the expansion layer byirradiating the medium with electromagnetic waves, wherein each of theprint device and the expansion device includes: a suction part forsucking the medium; and a discharge part for discharging the medium, andwherein the suction part of the print device and the suction part of theexpansion device are aligned along a lateral direction in which theprint device and the expansion device are aligned.

A system for forming a structure on a print medium includes: a printdevice for printing an electromagnetic wave-heat conversion layer forconverting electromagnetic waves into heat, on a medium including anexpansion layer that expands by heating; an expansion device alignedlaterally with the print device, for expanding the expansion layer byirradiating the medium with electromagnetic waves; a top plate coveringthe print device and the expansion device from above; and a display unitlocated above the expansion device, for displaying information.

According to the present invention, it is possible to enhanceworkability when manufacturing a structure using a system that combinesa device for forming an electromagnetic wave-heat conversion layer and adevice for irradiating with electromagnetic waves.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1A is a front view schematically illustrating a system for forminga structure on a print medium according to an embodiment of the presentinvention.

FIG. 1B is a plan view schematically illustrating the structuremanufacturing system according to the embodiment of the presentinvention.

FIG. 1C is a plan view schematically illustrating the system for forminga structure on a print medium according to the embodiment of the presentinvention in a closed state before pulling out a top plate.

FIG. 1D is a plan view schematically illustrating the system for forminga structure on a print medium according to the embodiment of the presentinvention in an open state after pulling out the top plate.

FIG. 2 is a perspective view of the system for forming a structure on aprint medium according to the embodiment of the present invention asseen from front left above.

FIG. 3 is a perspective view of the system for forming a structure on aprint medium according to the embodiment of the present invention asseen from back right above.

FIG. 4 is a perspective view of the system for forming a structure on aprint medium according to the embodiment of the present invention in anopen state after pulling out the top plate as seen from front leftabove.

FIG. 5 is a plan view illustrating the system for forming a structure ona print medium according to the embodiment of the present invention.

FIG. 6 is a right side view illustrating the system for forming astructure on a print medium according to the embodiment of the presentinvention.

FIG. 7 is a perspective view of the system for forming a structure on aprint medium according to the embodiment of the present invention asseen from front right above.

FIG. 8 is a perspective view of a frame in the embodiment of the presentinvention as seen from front right above.

FIG. 9A is a sectional view illustrating a structure manufacturingmedium in the embodiment of the present invention.

FIG. 9B is a sectional view illustrating a structure in the embodimentof the present invention.

FIG. 10 is a flowchart for describing a structure manufacturing methodin the embodiment of the present invention.

FIG. 11 is a diagram illustrating an example of the hardware structureof a computer capable of operating as a control unit in the embodimentof the present invention.

FIG. 12 is a perspective view illustrating a print unit body in theembodiment of the present invention.

FIG. 13 is a simplified sectional view illustrating the internalstructure of an expansion unit in the embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

The following describes a system for forming a structure on a printmedium according to an embodiment of the present invention withreference to drawings.

FIGS. 1A and 1B are a front view and plan view schematicallyillustrating a system for forming a structure on a print medium 1.

FIGS. 1C and 1D are plan views schematically illustrating the system forforming a structure on a print medium 1 in a closed state before pullingout a top plate 30 and an open state after pulling out the top plate 30.

FIGS. 2 and 3 are a perspective view of the system for forming astructure on a print medium 1 as seen from front left above and aperspective view of the system for forming a structure on a print medium1 as seen from back right above.

FIG. 4 is a perspective view of the system for forming a structure on aprint medium 1 in an open state after pulling out the top plate 30 asseen from front left above.

FIGS. 5, 6, and 7 are a front view, right side view, and perspectiveview as seen from front right above illustrating the system for forminga structure on a print medium 1.

FIG. 8 is a perspective view of a frame 60 as seen from front rightabove.

In FIGS. 1A to 8 and the below-mentioned FIGS. 12 and 13, the Xdirection (first direction) is the same as the direction (horizontaldirection) in which a print unit 10 and an expansion unit 20 arealigned, the Y direction (second direction) is the same as theconveyance direction D in which media M11 to M14 are conveyed asillustrated in FIGS. 12 and 13, and the Z direction is the same as thevertical direction. The X direction, the Y direction, and the Zdirection are orthogonal to each other.

As illustrated in FIGS. 1A to 7, the system for forming a structure on aprint medium 1 includes: the print unit 10 which is an example of aprint device; the expansion unit 20 which is an example of an expansiondevice; the top plate 30; a display unit 40; a control unit 50; and theframe 60.

The print unit 10 includes: a print unit body 300 illustrated in FIG. 12described later; a suction part (paper feed tray) 11 for sucking themedia M11 to M13; and a discharge part 12 for discharging media M12 toM14 obtained by printing the media M11 to M13. The print unit 10 printsa front electromagnetic wave-heat conversion layer 104 and a backelectromagnetic wave-heat conversion layer 106 illustrated in FIG. 9A onthe media M11 and M13, and prints a color ink layer 105 illustrated inFIG. 9A on the medium M12. This will be described in detail later.

The expansion unit 20 includes: a suction part (paper feed tray) 21 forsucking the medium M14; and a discharge part 22 for discharging themedium M14. The expansion unit 20 irradiates the medium M14 withelectromagnetic waves by an irradiation part 24 illustrated in FIG. 13to expand a foaming resin layer (foaming expansion layer) 102illustrated in FIG. 9A, thus manufacturing a structure M15 illustratedin FIG. 9B.

The print unit 10 and the expansion unit 20 are aligned in the firstdirection (X direction). The suction part 11 of the print unit 10 andthe suction part 21 of the expansion unit 20 are arranged on one side(back side) in the Y direction which is the second directionintersecting the first direction, and the discharge part 12 of the printunit 10 and the discharge part 22 of the expansion unit 20 are arrangedon the other side (front side) in the Y direction. In other words, thesuction part 11 of the print unit 10 and the suction part 21 of theexpansion unit 20 are aligned along the X direction in which the printunit 10 and the expansion unit 20 are aligned, on one side of the topplate 30 in the direction (Y direction) intersecting the X direction.Meanwhile, the discharge part 12 of the print unit 10 and the dischargepart 22 of the expansion unit 20 are aligned along the X direction, onthe opposite side of the top plate 30 to the one side in theintersecting direction. The discharge part 12 of the print unit 10 andthe discharge part 22 of the expansion unit 20 respectively face thesuction part 11 of the print unit 10 and the suction part 21 of theexpansion unit 20.

Here, the front side typically means the side on which an operator 400illustrated in FIGS. 1B to 1D faces the system for forming a structureon a print medium 1. The front side also refers to the lower side of thedisplay contents in the display unit 40 in the up-down direction. Theback side refers to the upper side of the display contents in thedisplay unit 40 in the up-down direction. The display orientation of thedisplay unit 40 may be changed optionally. Since the one side in the Ydirection is the back side and the other side in the Y direction is thefront side as mentioned above, the X direction which is the horizontaldirection orthogonal to (intersecting) the Y direction is also referredto as the lateral direction or the right-left direction. FIG. 1Billustrates an example of the display contents (a picture of mountains)displayed in the display unit 40.

The print unit 10 and the expansion unit 20 are desirably able to bepulled out to the front side as an example, in a state where a frontpanel 65 is removed. The below-mentioned control unit 50 is alsodesirably able to be pulled out to the front side as an example.

The top plate 30 covers the print unit 10 and the expansion unit 20 fromabove. The top plate 30 slides along the Y direction by a pair of rightand left slide mechanisms 67 of the frame 60 illustrated in FIG. 8,between a closed state illustrated in FIG. 1C, i.e. a state of coveringthe print unit 10 and the expansion unit 20 from above, and an openstate S illustrated in FIG. 1D, i.e. a state of being pulled out so thatthe upper parts of the print unit 10 and expansion unit 20 are open.Thus, the top plate 30 is slidable in the direction (Y direction)intersecting the X direction in which the print unit 10 and theexpansion unit 20 are aligned, by the slide mechanism 67. The top plate30 may not necessarily slide to such a position where the whole upperparts of the print unit 10 and expansion unit 20 are open, but isdesirably slidable to such a position where operations such asmaintenance can be performed on the print unit 10 and the expansion unit20. FIG. 1D illustrates the structure M15 manufactured using the systemfor forming a structure on a print medium 1, together with the media M12to M14 which are intermediate products during the manufacture of thestructure M15. In FIG. 1D, the media M12 to M14 printed in the sameup-down direction as the display contents of the display unit 40 areoutput.

The display unit 40 displays information about at least one of the printunit 10 and expansion unit 20. As illustrated in FIG. 1A, the uppersurface of the display unit 40 is desirably coplanar with the uppersurface of the top plate 30. The display unit 40 may include a touchpanel for operating at least one of the print unit 10 and expansion unit20.

The center C2 of the display unit 40 in the X direction is shifted moreto the expansion unit 20 side than the center C1 of the top plate 30 inthe X direction. In other words, the display unit 40 is shifted more tothe expansion unit 20 side than the center C1 of the top plate 30 in theX direction, that is, incorporated at a position close to the end of thetop plate 30 in the X direction. The display unit 40 may be shifted moreto the print unit 10 side than the center C1 of the top plate 30 in theX direction. However, in the case where the operator 400 is seatedfacing the expansion unit 20 in order to avoid the legs of the seatedoperator 400 touching the control unit 50 given that the control unit 50is located directly below the print unit 10 as described later, thedisplay unit 40 is desirably shifted more to the expansion unit 20 sidein terms of the visibility of the operator 400.

An operation unit for operating at least one of the print unit 10 andexpansion unit 20 may be located instead of or together with the displayunit 40. In this case, for example, the operation unit may includebuttons, switches, and dials, and be incorporated in or placed on thetop plate 30.

As illustrated in FIG. 1A, the control unit 50 is located directly belowthe print unit 10. The term “directly below” means that at least part ofthe control unit 50 is located below the center of the print unit 10 inthe X direction and the Y direction, and at least part of the print unit10 is located above the center of the control unit 50 in the X directionand the Y direction.

The control unit 50 includes a control part for controlling at least oneof the print unit 10, expansion unit 20, and display unit 40. Thecontrol unit 50 may include a power supply part for supplying power toat least one of the print unit 10, expansion unit 20, and display unit40. As illustrated in FIGS. 2 and 5, an emergency stop button 51 forstopping the operation of at least one of the print unit 10 andexpansion unit 20 is provided in the lower part of the control unit 50.The emergency stop button 51 is desirably provided on the front side ofthe control unit 50 facing the operator 400.

As illustrated in FIG. 6, the front end (the left end in FIG. 6) of thecontrol unit 50 is located more on the back side (the right side in FIG.6) than the front end of the print unit 10 (and the expansion unit 20).As illustrated in FIG. 5, the right end of the control unit 50 islocated more on the left side than the right end of the print unit 10.Therefore, the control unit 50 is not easily visible from the front sideand the right side, as illustrated in FIG. 7. In the case where thecontrol unit 50 is not visible, simpler external appearance is presentedto the operator 400 and so design is enhanced, as compared with the casewhere the control unit 50 is visible.

As illustrated in FIG. 8, the frame 60 includes: a pair of side bases61; a pair of side panels 62; four movable legs 63; four fixed legs 64;the front panel 65 illustrated in FIGS. 2, 5, and 7; a back panel 66illustrated in FIG. 3; the pair of slide mechanisms 67; two upperconnection beams 68; and three lower connection beams 69.

The pair of side bases 61 are each shaped like a trapezoidal frame (or asubstantially rectangular frame) whose lower side is longer than theupper side and whose corners are round (curved) in a side view. The pairof side bases 61 are each provided with a support beam 61 a extending inthe Y direction to support the ends of the three lower connection beams69 the upper parts of which have the print unit 10 and the expansionunit 20 fixed thereto.

The pair of side panels 62 each extend from the upper end of the sidebase 61 to the support beam 61 a so as to cover at least the upper halfof the hollow portion of the side base 61 while leaving the rest of thehollow portion on the lower side in a side view. As illustrated in FIGS.5 and 6, the pair of side panels 62 each extend from the upper end ofthe side base 61 to a lower position than the lower ends of the printunit 10 and expansion unit 20 in a side view. The print unit 10 and theexpansion unit 20 do not extend off the side base 61 and the side panel62 except the suction parts 11 and 21 in a side view. In terms ofpresenting simple external appearance to the operator 400 to enhancedesign, the print unit 10 and the expansion unit 20 are desirably noteasily visible from the right or left as mentioned above. Although theside panel 62 may cover the whole hollow portion of the side base 61,the side panel 62 desirably covers only part of the hollow portion interms of saving material cost.

The movable legs 63 are casters for enabling the transportation of thesystem for forming a structure on a print medium 1, and a total of fourmovable legs 63, that is, two movable legs 63 for each side base 61, areprovided. A total of four fixed legs 64, that is, two fixed legs 64 foreach side base 61 between two movable legs 63, are provided. The fixedlegs 64 are desirably adjustable in height between an upper positionwhere the transportation of the system for forming a structure on aprint medium 1 is enabled and a lower position where the fixed legs 64are in contact with the ground to disable the movement of the system forforming a structure on a print medium 1.

As illustrated in FIGS. 2, 5, and 7, the front panel 65 covers the frontside of the print unit 10 and expansion unit 20, and is open at thedischarge parts 12 and 22. The front panel 65 extends from the upper endof each side base 61 to a lower position than the lower ends of theprint unit 10 and expansion unit 20 as with the side panels 62, toenhance design. The lower end of the front panel 65 is at substantiallythe same height as the lower ends of the pair of side panels 62 or thesupport beams 61 a. The front panel 65 is desirably attached and removedeasily.

A first surface 65 a of the front panel 65 on the front side of theprint unit 10 projects more to the front than a second surface 65 b ofthe front panel 65 on the front side of the expansion unit 20. Thus,there is a difference in level between the first surface 65 a and thesecond surface 65 b each extending in the X direction and Z direction.The first surface 65 a and second surface 65 b of the front panel 65 arelocated more on the back side than the front end of each side base 61.

As illustrated in FIG. 3, the back panel 66 covers the back side of theprint unit 10 and expansion unit 20, and is open at the suction parts 11and 21. The back panel 66 extends from the upper end of each side base61 to a lower position than the lower ends of the print unit 10 andexpansion unit 20 between the pair of side bases 61, to enhance designas with the side panels 62. The lower end of the back panel 66 is atsubstantially the same height as the lower ends of the pair of sidepanels 62 or the support beams 61 a. The back panel 66 is desirablyattached and removed easily.

The back panel 66 lies along the back end of each side base 61. Theupper part of the back panel 66 thus includes a curved part 66a curvedalong the curved part at the back upper end of the side base 61.

The pair of slide mechanisms 67 illustrated in FIG. 8 are provided atthe upper ends of the facing surfaces of the respective pair of sidebases 61 a. Each slide mechanism 67 includes: a slider 67 a fixed to,for example, the part of the top plate 30 projecting downward from bothends in the X direction; and a guide rail 67 b for guiding the slider 67a to move in the Y direction. Each slide mechanism 67 thus slides thetop plate 30 in the Y direction as mentioned above.

The two upper connection beams 68 extend between the pair of side bases61 to connect the pair of side bases 61. One of the two upper connectionbeams 68 is fixed to the upper back end of each of the pair of sidebases 61, and the other one of the two upper connection beams 68 isfixed to the side base 61 and the guide rail 67 b in the lower part ofthe front end of the guide rail 67 b.

The three lower connection beams 69 extend between the support beams 61a of the pair of side bases 61 to connect the pair of side bases 61,apart from each other in the Y direction. The print unit 10 and theexpansion unit 20 are fixed to the upper parts of the three lowerconnection beams 69. In other words, the three lower connection beams 69are located below the print unit 10 and the expansion unit 20. Thecontrol unit 50 is fixed to the lower parts of the three lowerconnection beams 69. The three lower connection beams 69 are thusprovided on the back side.

One of the three lower connection beams 69 is fixed to the back ends ofthe support beams 61 a and the back side of the pair of side bases 61,and the other two of the three lower connection beams 69 are locatednear the center of the support beams 61 a in the Y direction. The threelower connection beams 69 are not located on the front side of thesupport beams 61 a (the front side of the side bases 61), so as not tointerfere with the operation of the operator 400 during the maintenanceof the system for forming a structure on a print medium 1 and the like.

Since the top plate 30 is located above the two upper connection beams68 and the print unit 10 and the expansion unit 20 ae located above thethree lower connection beams 69, the upper connection beams 68 and thelower connection beams 69 are also not easily visible from the outside.

FIG. 9A is a sectional view illustrating the structure manufacturingmedium M14 in this embodiment. FIG. 9B is a sectional view illustratingthe structure M15 in this embodiment.

The medium M14 illustrated in FIG. 9A is in a state before expanding thefoaming resin layer 102 by heating. As illustrated in FIG. 13, themedium M14 is inserted into the expansion unit 20 from the suction part21 of the expansion unit 20 and irradiated with electromagnetic waves bythe irradiation part 24, as a result of which the foaming resin layer102 expands by heating and the structure M15 illustrated in FIG. 9B ismanufactured.

The medium M11 in which a base material 101, the foaming resin layer102, and an ink receiving layer 103 are stacked in order is insertedinto the print unit 10 from the suction part 11 of the print unit 10.The front electromagnetic wave-heat conversion layer 104 is then printedon the medium M11 in the print unit body 300 illustrated in FIG. 12 asan example, and the resulting medium is discharged from the dischargepart 12. A color ink layer 105 is printed on the medium M12 in which thefront electromagnetic wave-heat conversion layer 104 has been printed.Moreover, the back electromagnetic wave-heat conversion layer 106 isprinted on the medium M13 in which the color ink layer 105 has beenprinted. The front electromagnetic wave-heat conversion layer 104 andthe back electromagnetic wave-heat conversion layer 106 are each anexample of an electromagnetic wave-heat conversion layer for convertingelectromagnetic waves into heat. The color ink layer 105 is an exampleof an image layer.

The base material 101 is made of, for example, paper, cloth such ascanvas, or a panel material such as plastic, although the material isnot particularly limited.

In the foaming resin layer 102, a thermal foaming agent (thermallyexpandable microcapsules) is distributed in a binder which isthermoplastic resin provided on the base material 101. The foaming resinlayer 102 thus foams to expand according to the amount of absorbed heat.The foaming resin layer 102 is an example of an expansion layer thatexpands by heating.

The ink receiving layer 103 is formed with a thickness of 10 μm as anexample, so as to cover the whole upper surface of the foaming resinlayer 102. The ink receiving layer 103 is made of a suitable materialfor receiving printing ink used for an inkjet printer, printing tonerused for a laser printer, ink of a ballpoint pen or fountain pen,graphite of a pencil, or the like and fixing it at least to the surface,and may be a general-purpose ink receiving layer used for inkjetprinting paper and the like.

Each of the ink receiving layer 103, front electromagnetic wave-heatconversion layer 104, and back electromagnetic wave-heat conversionlayer 106, in the case of having elasticity, deforms with the foamingexpansion of the foaming resin layer 102, which suppresses the formationof a clearance between the foaming resin layer 102 and the ink receivinglayer 103, between the ink receiving layer 103 and the frontelectromagnetic wave-heat conversion layer 104, and between the basematerial 101 and the back electromagnetic wave-heat conversion layer106. The formation of such a clearance may cause a reduction in theamount of heat transferred from the front electromagnetic wave-heatconversion layer 104 to the foaming resin layer 102.

FIG. 10 is a flowchart for describing a structure manufacturing methodin this embodiment.

First, the aforementioned medium M11 is prepared. Next, black ink (blackmaterial) including carbon black is inkjet printed as the frontelectromagnetic wave-heat conversion layer 104 in the part where theexpansion layer 102 is to be expanded on the first surface of the mediumM11 provided with the expansion layer 102, i.e. the front surface of theink receiving layer 103, using the print unit body 300 which is ageneral-purpose inkjet printer illustrated in FIG. 12. As a result, thefront electromagnetic wave-heat conversion layer 104 is formed (stepS11: first surface electromagnetic wave-heat conversion layer formationstep). The medium M11 on which the front electromagnetic wave-heatconversion layer 104 has been formed is referred to as the medium M12.

The print unit body 300 reads a gray scale value set for each coordinateand, based on the read value, prints the black material (black ink)while controlling its density by area coverage modulation as an example.The front electromagnetic wave-heat conversion layer 104 is made of amaterial that converts electromagnetic waves into heat energy moreeasily than the materials of the base material 101, foaming resin layer102, and ink receiving layer 103 included in the medium M11. The frontelectromagnetic wave-heat conversion layer 104 may be any layer thatconverts electromagnetic waves into heat, and may be a layer other thana layer formed by the print unit body 300.

The same applies to the back electromagnetic wave-heat conversion layer106. Here, in the case where the front electromagnetic wave-heatconversion layer 104 is irradiated with the same amount ofelectromagnetic waves, the foaming resin layer 102 absorbs more heatenergy in the region corresponding to the part where the density (e.g.area coverage modulation) of the front electromagnetic wave-heatconversion layer 104 is higher. Basically, the foaming height of thefoaming resin layer 102 is positively correlated with the amount of heatabsorbed by the foaming resin layer 102. Hence, the foaming height ofthe foaming resin layer 102 is higher in the part where the density ofthe front electromagnetic wave-heat conversion layer 104 or backelectromagnetic wave-heat conversion layer 106 is higher. The shading ofthe front electromagnetic wave-heat conversion layer 104 is accordinglydetermined to correspond to the target height of the three-dimensionalshape formed by the foaming expansion of the foaming resin layer 102, aswith the below-mentioned back electromagnetic wave-heat conversion layer106.

Following this, color inks of three colors of cyan C, magenta M, andyellow Y as coloring materials are inkjet printed on the first surfaceof the medium M12, i.e. the front surface provided with the frontelectromagnetic wave-heat conversion layer 104, using the print unitbody 300 illustrated in FIG. 12. The color ink layer 105 is thus formed(step S12: image layer formation step). The medium M12 on which thecolor ink layer 105 has been formed is referred to as the medium M13.

Here, when black ink including carbon black is used in the image layerformation step S12, heat generated by converting electromagnetic wavesby this black ink part transfers to the foaming resin layer 102, as aresult of which a desired foaming state of the foaming resin layer 102cannot be achieved. Hence, the color of black or gray in the color inklayer 105 may be formed using a color mixture of cyan C, magenta M, andyellow Y or using black ink that does not absorb heat energy, i.e. inkof black K not including carbon black. Alternatively, in considerationof the heat absorptivity of each part of the color ink layer 105, suchheat absorptivity may be deducted to determine the heat absorptivity,i.e. shading, of the front heat conversion layer 104.

Since the density of the color ink layer 105 decreases as the foamingresin layer 102 foams to expand and the surface area of the foamingresin layer 102 increases, visual coloration becomes lighter after thebelow-mentioned foaming expansion of the foaming resin layer 102 thanbefore the foaming expansion. In view of this, the color ink layer 105may be set so as to have desired visual coloration after the expansionof the foaming resin layer 102. In detail, the formation density of thecolor ink layer 105 to be formed in the part where the expansion of thefoaming resin layer 102 is set to be greater may be higher.

In the image layer formation step S12, a black ink layer may be formedby monochrome printing instead of forming the color ink layer 105. Thecolor ink layer 105 or the black ink layer may be formed by means otherthan the print unit body 300 which is an inkjet printer, such as a laserprinter.

Next, black ink (black material) including carbon black is inkjetprinted on the second surface opposite to the first surface providedwith the expansion layer 102 in the medium M11, i.e. the back surface ofthe base material 101, using the print unit body 300 illustrated in FIG.12. The back electromagnetic wave-heat conversion layer 106 is thusformed (step S13: second surface electromagnetic wave-heat conversionlayer formation step). The medium M13 on which the back electromagneticwave-heat conversion layer 106 has been formed is referred to as themedium M14. The method of forming the back electromagnetic wave-heatconversion layer 106 may be the same as that of the frontelectromagnetic wave-heat conversion layer 104. One of the frontelectromagnetic wave-heat conversion layer 104 and back electromagneticwave-heat conversion layer 106 may be omitted. The back electromagneticwave-heat conversion layer 106 may be formed before forming the frontelectromagnetic wave-heat conversion layer 104, or after forming thefront electromagnetic wave-heat conversion layer 104 and before formingthe color ink layer 105.

Next, the medium M14 is irradiated with electromagnetic waves from thesecond surface, i.e. the back electromagnetic wave-heat conversion layer106 (step S14: second surface electromagnetic wave irradiation step),and then irradiated with electromagnetic waves from the first surface,i.e. the color ink layer 105 (step S15: first surface electromagneticwave irradiation step). The first surface electromagnetic waveirradiation step S15 may be performed before or simultaneously with thesecond surface electromagnetic wave irradiation step S14. In the casewhere one of the front electromagnetic wave-heat conversion layer 104and back electromagnetic wave-heat conversion layer 106 is omitted, thesecond surface electromagnetic wave irradiation step S14 or the firstsurface electromagnetic wave irradiation step S15 is omittedaccordingly.

The second surface electromagnetic wave irradiation step S14 and thefirst surface electromagnetic wave irradiation step S15 may be steps forexpanding the foaming resin layer 102 by heating through irradiationwith electromagnetic waves in a wavelength region absorbed by the backelectromagnetic wave-heat conversion layer 106 and the frontelectromagnetic wave-heat conversion layer 104, and are performed by theirradiation part 24 illustrated in FIG. 13. In particular, the backelectromagnetic wave-heat conversion layer 106 and the frontelectromagnetic wave-heat conversion layer 104 each convertelectromagnetic waves into heat, and the heat is transferred to thethermal foaming agent included in the foaming resin layer 102, as aresult of which the thermal foaming agent undergoes expansion reaction.The foaming resin layer 102 foams to expand according to the blackdensity of each of the back electromagnetic wave-heat conversion layer106 and front electromagnetic wave-heat conversion layer 104. Astructure is manufactured from the medium M11 in this way. Even when thepart of the foaming resin layer 102 where neither the backelectromagnetic wave-heat conversion layer 106 nor the frontelectromagnetic wave-heat conversion layer 104 is not formed absorbsheat energy, the amount of heat is sufficiently small, so that theheight does not change substantially or the height changes sufficientlysmall as compared with the part where the back electromagnetic wave-heatconversion layer 106 or the front electromagnetic wave-heat conversionlayer 104 is formed.

The wavelength of the electromagnetic waves with which the backelectromagnetic wave-heat conversion layer 106 and the frontelectromagnetic wave-heat conversion layer 104 are irradiated may bechanged as appropriate according to the back electromagnetic wave-heatconversion layer 106 and the front electromagnetic wave-heat conversionlayer 104. Carbon black used in the back electromagnetic wave-heatconversion layer 106 and the front electromagnetic wave-heat conversionlayer 104 tends to absorb electromagnetic waves of wavelengths that arecentered on a near-infrared region (750 nm to 1400 nm) and include avisible light region (380 nm to 750 nm) and a mid-infrared region (1400nm to 4000 nm), as compared with electromagnetic waves of otherwavelengths. A material other than carbon black may be used as the backelectromagnetic wave-heat conversion layer 106 and the frontelectromagnetic wave-heat conversion layer 104, and electromagneticwaves of a desired wavelength region out of the whole wavelength regionmay be applied depending on the material used. Thus, depending on thematerial, electromagnetic waves of other wavelengths may be applied suchas a near-ultraviolet region (200 nm to 380 nm), a far-ultravioletregion (10 nm to 200 nm), or an infrared region (4000 nm to 15000 nm)other than near-infrared and mid-infrared. These numerals are merely anexample, and the wavelength region boundaries are not limited to thesenumerals.

The control unit 50 may be a computer 200 illustrated in FIG. 11, thatis, a computer including a central processing unit (CPU) 201, a storageunit 202, an input unit 203, an interface unit 204, and a recordingmedium drive unit 205. These components are connected via a bus line206, and transfer various data with each other.

The CPU 201 is a processor for controlling the overall operation of thecomputer 200. The CPU 201 reads and executes a structure manufacturingprogram to control the manufacture of the structure.

The storage unit 202 includes read only memory (ROM), random accessmemory (RAM), a hard disk, etc.

The ROM is read only semiconductor memory in which a predetermined basiccontrol program is recorded beforehand. Nonvolatile memory that canstore data when power supply is off, such as flash memory, may be usedas the ROM.

The RAM is readable and writable semiconductor memory used as a workingstorage area according to need when the CPU 201 executes various controlprograms.

The hard disk stores various control programs executed by the CPU 201and various data.

The input unit 203 is, for example, a keyboard device and a mousedevice. When operated by the user of the computer 200, the input unit203 acquires input information from the user associated with theoperation, and sends the acquired input information to the CPU 201.

The interface unit 204 manages the transfer of various informationbetween various devices.

The recording medium drive unit 205 is a device for reading variouscontrol programs and data recorded in a portable recording medium 207.The CPU 201 may read and execute a predetermined control programrecorded in the portable recording medium 207 through the recordingmedium drive unit 205, to perform each process for structuremanufacturing.

Examples of the portable recording medium 207 include compact disc readonly memory (CD-ROM), digital versatile disc read only memory (DVD-ROM),and flash memory including a USB connector.

To cause the computer 200 to operate as the control unit 50 of thesystem for forming a structure on a print medium 1, first a controlprogram for causing the CPU 201 to perform each process is generated.The generated control program is stored in the hard disk device in thestorage unit 202 or the portable recording medium 207 beforehand. When apredetermined instruction is issued to the CPU 201, the CPU 201 readsand executes the control program. The computer 200 thus operates as thecontrol unit 50.

FIG. 12 is a perspective view illustrating the print unit body 300 inthis embodiment.

The print unit body 300 is placed inside the print unit 10, and includesa carriage 301 capable of reciprocating in the direction, indicated bythe two-headed arrow a, orthogonal to the medium conveyance direction. Aprint head 302 for executing printing and an ink cartridge 303 (303 w,303 c, 303 m, 303 y) storing ink are attached to the carriage 301.

The cartridges 303 w, 303 c, 303 m, and 303 y respectively store colorinks of white W, cyan C, magenta M, and yellow Y. These cartridges areindividually disposed separately from each other, or the ink chambersare integrated into one housing. The cartridges are connected to theprint head 302 having nozzles for ejecting the respective color inks.

The carriage 301 is slidably supported by a guide rail 304 on one side,and fastened to a toothed drive belt 305 on the other side. Thus, theprint head 302 and the ink cartridge 303 (303 w, 303 c, 303 m, 303 y)reciprocate in the direction, indicated by the two-headed arrow a inFIG. 12, orthogonal to the conveyance direction D, i.e. in the printmain scanning direction, together with the carriage 301.

A flexible communication cable 306 is connected between the print head302 and the control unit 50 via an internal frame 307. Hence, print dataand print control data are output to the print head 302 via the flexiblecommunication cable 306, and the print head 302 is controlled based onthese data.

A platen 308 is provided in the lower part of the internal frame 307 atthe position facing the print head 302, so as to extend in the mainscanning direction of the print head 302. The platen 308 constitutespart of the medium conveyance path. Each of the medium M11 on which thefront electromagnetic wave-heat conversion layer 104 is formed, themedium M12 on which the color ink layer 105 is formed, and the mediumM13 on which the back electromagnetic wave-heat conversion layer 106 isformed is, in a state where its lower surface is in contact with theplaten 308, intermittently conveyed in the print sub-scanning directionindicated by the arrow b in FIG. 12 which is the conveyance direction D,by a suction roller pair 409 (the lower roller is hidden behind themedium M11, M12, or M13 and is not visible in FIG. 12) and a dischargeroller pair 310 (the lower roller is equally not visible). The suctionroller pair 309 and the discharge roller pair 310 are controlled by thecontrol unit 50.

The control unit 50 controls a motor 311, the print head 302, thesuction roller pair 309, and the discharge roller pair 310, to conveythe print head 302 to an appropriate position in the main scanningdirection together with the carriage 301 via the drive belt 305connected to the motor 311. Moreover, during the period in which theconveyance of the medium M12 is stopped, the control unit 50 causes theprint head 302 to direct a jet of color ink drops of cyan C, magenta M,and yellow Y and a jet of black ink drops of black K toward the mediumM12, to print the color ink layer 105 on the medium M12. During theperiod in which the conveyance of the medium M11 or the medium M13 isstopped, the control unit 50 causes the print head 302 to direct a jetof black ink drops of black K toward the medium M11 or the medium M13,to print the front electromagnetic wave-heat conversion layer 104 on themedium M11 or the back electromagnetic wave-heat conversion layer 106 onthe medium M13.

FIG. 13 is a simplified sectional view of the internal structure of theexpansion unit 20 in this embodiment.

As illustrated in FIG. 13, the expansion unit 20 includes theaforementioned suction part 21 and discharge part 22, a housing 23, andthe irradiation part 24 placed inside the housing 23. In the expansionunit 20, the medium M14 sucked from the suction part 21 is conveyed by aconveyance roller 21 a of the suction part 21 and a conveyance roller 23a of the housing 23 which are an example of a conveyance part, whilebeing guided by a conveyance guide 21 b of the suction part 21 and aconveyance guide 23 b of the housing 23.

The irradiation part 24 irradiates the medium M14 with electromagneticwaves, as mentioned above. The irradiation part 24 is, for example, ahalogen lamp, and applies light of a near-infrared region (750 nm to1400 nm).

In the embodiment described above, the system for forming a structure ona print medium 1 includes: the print unit 10 which is an example of aprint device for printing the front electromagnetic wave-heat conversionlayer 104 and the back electromagnetic wave-heat conversion layer 106which are an example of an electromagnetic wave-heat conversion layerfor converting electromagnetic waves into heat, on the media M11 and M13including the foaming resin layer 102 which is an example of anexpansion layer that expands by heating; the expansion unit 20 which isan example of an expansion device aligned laterally (X direction) withthe print unit 10, for expanding the foaming resin layer 102 byirradiating the medium M14 with electromagnetic waves; and the top plate30 covering the print unit 10 and expansion unit 20 from above.

By performing the electromagnetic wave-heat conversion layer formationand the electromagnetic wave irradiation independently of each other inthe independent print unit 10 and expansion unit 20, the electromagneticwave-heat conversion layer formation and the electromagnetic waveirradiation can be performed at desired timings by dedicated devices.This eases the manufacture of a structure in a desired foaming expansionstate. Meanwhile, the operator 400 performs the operation of insertingand removing the medium M12, M13, or M14 on each of the print unit 10and expansion unit 20. In this embodiment, however, the print unit 10and the expansion unit 20 are aligned laterally, and the top plate 30 islocated above the print unit 10 and the expansion unit 20, so that theoperator 400 can perform operation on the print unit 10 and theexpansion unit 20 at the same level of height while simply facing thesystem for forming a structure on a print medium 1 without moving orwith a slight movement. This enhances workability. Workability is alsoenhanced as the media M11 to M14 or objects relating to other operationscan be put on the top plate 30. Thus, according to this embodiment,workability is enhanced when manufacturing a structure using a systemthat combines a device (print unit 10) for forming an electromagneticwave-heat conversion layer and a device (expansion unit 20) forirradiating with electromagnetic waves.

In this embodiment, the display unit 40 for displaying information aboutat least one of the print unit 10 and expansion unit 20 is incorporatedin the top plate 30. This enables the operator 400 to perform otheroperation on the top plate 30 while viewing the display unit 40incorporated in the top plate 30, which further enhances workability.

In this embodiment, the upper surface of the display unit 40 is coplanarwith the upper surface of the top plate 30. This eases operation on thetop plate 30, which further enhances workability.

In this embodiment, the display unit 40 is located close to the end ofthe top plate 30 in the lateral direction (X direction) in which theprint unit 10 and the expansion unit 20 are aligned. This enablesoperation to be performed in the space on the top plate 30 opposite tothe side where the display unit 40 is located close to the end, whichfurther enhances workability.

In this embodiment, the suction part 11 of the print unit 10 and thesuction part 21 of the expansion unit 20 are aligned along the lateraldirection (X direction) in which the print unit 10 and the expansionunit 20 are aligned, on one side of the top plate 30 in the direction (Ydirection) intersecting the lateral direction. The discharge part 12 ofthe print unit 10 and the discharge part 22 of the expansion unit 20 arealigned along the lateral direction (X direction), on the opposite sideof the top plate 30 to the one side in the intersecting direction (Ydirection). This enables the insertion and removal of the medium on theprint unit 10 and the expansion unit 20 to be performed from the sameside. This further enhances workability as, for example, the print stateor the foaming expansion state can be easily checked from the front sidewhere the discharge parts 12 and 22 are provided.

In this embodiment, the slide mechanisms 67 slide the top plate 30 inthe direction (Y direction) intersecting the lateral direction (Xdirection) in which the print unit 10 and the expansion unit 20 arealigned. By sliding the top plate 30 to open the upper parts of theprint unit 10 and expansion unit 20 in this way, ink replacement in theprint unit 10, maintenance such as clearing a jam in the print unit 10and the expansion unit 20, and other operation can be carried out. Thisfurther enhances workability.

In this embodiment, the control unit 50 is located directly below theprint unit 10. This prevents the electronic parts included in thecontrol unit 50 and the like from being damaged due to high-temperatureenvironment, as compared with the case where the control unit 50 islocated directly below the expansion unit 20 which tends to be higher intemperature than the print unit 10.

While an embodiment of the present invention has been described above,the invention of the present application includes the inventions definedin the claims and their equivalent scope. The inventions defined in theclaims in the present application as originally filed are as follows.

What is claimed is:
 1. A system for forming a structure on a printmedium, the system comprising: a print device for printing anelectromagnetic wave-heat conversion layer for convertingelectromagnetic waves into heat, on a medium including an expansionlayer that expands by heating; an expansion device aligned laterallywith the print device, for expanding the expansion layer by irradiatingthe medium with electromagnetic waves; a top plate covering the printdevice and the expansion device from above; and a slide mechanism forsliding the top plate in a direction intersecting a lateral direction inwhich the print device and the expansion device are aligned.
 2. Thesystem for forming a structure on a print medium according to claim 1,further comprising a display unit for displaying information about atleast one of the print device and the expansion device, wherein thedisplay unit is incorporated in the top plate.
 3. The system for forminga structure on a print medium according to claim 2, wherein an uppersurface of the display unit is coplanar with an upper surface of the topplate.
 4. The system for forming a structure on a print medium accordingto claim 2, wherein the display unit is incorporated at a position closeto an end of the top plate in the lateral direction in which the printdevice and the expansion device are aligned.
 5. The system for forming astructure on a print medium according to claim 2, wherein a center ofthe display unit is located more on an expansion device side than acenter of the top plate.
 6. The system for forming a structure on aprint medium according to claim 1, further comprising a pair of sidebases, wherein the pair of side bases are each shaped like a frame whoselower side is longer than an upper side thereof and whose corners areround.
 7. The system for forming a structure on a print medium accordingto claim 6, wherein the pair of side bases are provided with arespective pair of side panels, and wherein the pair of side panels eachcover at least an upper half of a hollow portion of a corresponding oneof the pair of side bases.
 8. The system for forming a structure on aprint medium according to claim 7, wherein the pair of side panels eachcover the hollow portion of the corresponding one of the pair of sidebases, to a lower position than a lower end of each of the print deviceand the expansion device.
 9. A system for forming a structure on a printmedium, the system comprising: a print device for printing anelectromagnetic wave-heat conversion layer for convertingelectromagnetic waves into heat, on a medium including an expansionlayer that expands by heating; an expansion device aligned laterallywith the print device, for expanding the expansion layer by irradiatingthe medium with electromagnetic waves; and a top plate covering theprint device and the expansion device from above, wherein each of theprint device and the expansion device includes: a suction part forsucking the medium; and a discharge part for discharging the medium, andwherein the suction part of the print device and the suction part of theexpansion device are aligned along a lateral direction in which theprint device and the expansion device are aligned, on a back side whichis one side of the top plate in a direction intersecting the lateraldirection.
 10. The system for forming a structure on a print mediumaccording to claim 9, wherein the discharge part of the print device andthe discharge part of the expansion device are aligned along the lateraldirection, on a front side which is an opposite side to the back side inthe intersecting direction.
 11. The system for forming a structure on aprint medium according to claim 9, further comprising a control unitlocated directly below the print device.
 12. The system for forming astructure on a print medium according to claim 11, wherein the controlunit controls at least one of the print device and the expansion device,and wherein a stop button for stopping operation of at least one of theprint device and the expansion device is provided on a front side of thecontrol unit.
 13. The system for forming a structure on a print mediumaccording to claim 12, wherein a front end of the control unit islocated more on a back side than a front end of each of the print deviceand the expansion device.
 14. The system for forming a structure on aprint medium according to claim 9, further comprising a back panelcovering a back side of the print device and the expansion device,wherein the back panel is open at a position corresponding to thesuction part of the print device and the suction part of the expansiondevice.
 15. The system for forming a structure on a print mediumaccording to claim 14, further comprising a pair of side bases, whereinthe back panel extends from an upper end of the pair of side bases to alower position than a lower end of each of the print device and theexpansion device.
 16. The system for forming a structure on a printmedium according to claim 15, wherein an upper part of the back panellies along a back side of the pair of side bases, in a curved shape. 17.A system for forming a structure on a print medium comprising: a printdevice for printing an electromagnetic wave-heat conversion layer forconverting electromagnetic waves into heat, on a medium including anexpansion layer that expands by heating; and an expansion device alignedlaterally with the print device, for expanding the expansion layer byirradiating the medium with electromagnetic waves, wherein each of theprint device and the expansion device includes: a suction part forsucking the medium; and a discharge part for discharging the medium, andwherein the suction part of the print device and the suction part of theexpansion device are aligned along a lateral direction in which theprint device and the expansion device are aligned.
 18. The system forforming a structure on a print medium according to claim 17, wherein thedischarge part of the print device and the discharge part of theexpansion device respectively face the suction part of the print deviceand the suction part of the expansion device.